Masonry structure

ABSTRACT

An apparatus and a method of producing the same are disclosed. The apparatus comprises a panel, a plurality of fasteners, and a plurality of bricks secured to the panel by the fastener.

The patent application claims priority to and herein incorporates byreference Provisional Patent Application No. 61/106,057, entitled“Masonry Structure” and filed on Oct. 16, 2008.

BACKGROUND

1. Field

The present disclosure is related to the field of masonry structures,and more specifically to factory-built masonry structures.

2. Background

Traditional masonry structures such as fireplaces, countertops, brickwalls and other hearth products are constructed by a mason and thus canbe expensive. Furthermore, they are built on-site and can requiresignificant time to be completed. Because of the above, in recent years,pre-built fireplaces have become popular. Also, factory built fireplacesare an attractive alternative because they can be installed inmulti-level buildings.

In designing factory-built fireplace, one goal has been to designfireplaces that resemble traditional masonry built fireplaces. Forexample, recent designs of factory-built fireplaces have incorporatedrefractory panels. However, such refractory panels, and other similardesigns, have been incapable of achieving the desired masonry look. Inan attempt to create a better masonry look, designers have added bricksto the firebox areas of the factory built fireplaces. However, suchconstruction designs have shown to be structurally unstable, oftenfalling and breaking, and thus unable to provide an adequate retentionof the bricks. Additionally, in such designs, bricks are usually poorlyaligned and do not tend to be capable of providing multiple brickpattern arrangements.

SUMMARY

In one aspect of the disclosure, an apparatus includes a panel, aplurality of fasteners, and a plurality of bricks secured to the panelby the fasteners.

In another aspect of the disclosure, a method of assembling a masonrystructure includes arranging a plurality of bricks with a panel, andsecuring the bricks to the panel with a plurality of fasteners.

In yet another aspect of the disclosure, an apparatus includes a panel,a plurality of bricks, and means for fastening the bricks to the panel.

In a further aspect of the disclosure, a fireplace includes a fireboxhaving a plurality of walls defining an area for a fire, each of thewalls having a panel, a plurality of fasteners, and a plurality ofbricks secured to the panel by the fasteners.

It is understood that other aspects of the present disclosure willbecome readily apparent to those skilled in the art from the followingdetailed description, wherein it is shown and described only exemplaryaspects of the disclosure by way of illustration. As will be realized,the disclosure includes other and different aspects and its severaldetails are capable of modification in various other respects, allwithout departing from the spirit and scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the present disclosure are illustrated by way ofexample, and not by way of limitation, in the accompanying drawings,wherein:

FIG. 1A is an elevated frontal view of a factory-built fireplace havingmasonry panels installed therein.

FIG. 1B is a side view of the fireplace of FIG. 1A.

FIG. 2 is an exploded view of the fireplace illustrated in FIG. 1Aillustrating the masonry panels installed on the rear wall, sidewallsand base of the fireplace cavity.

FIG. 3 is a top view of a masonry panel for the base of the fireplacehaving a herringbone pattern.

FIG. 4 illustrates a secure placement of a plurality of bricks on apanel

FIG. 5 shows a rivet inserted into a brick.

FIG. 6 shows the rivet of FIG. 5 after it has been expanded due to thefull insertion of its mandrel.

FIG. 7 shows the rear view of the panel of FIG. 4. The panel comprises aplurality of stiffeners.

FIG. 8 illustrates a structure of one of the stiffeners from FIG. 7.

FIG. 9 illustrates a method of fastening bricks 95 a onto the panel ofFIG. 4.

FIG. 10 illustrates one method of cutting of the panel with installedbricks.

FIG. 11 illustrates another method of cutting the panel with installedbricks.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appendeddrawings is intended as a description of various aspects of the presentdisclosure and is not intended to represent all ways in which thepresent disclosure may be practiced. The detailed description mayinclude specific details for the purpose of providing a thoroughunderstanding of the present disclosure; however, it will be apparent tothose skilled in the art that the various aspects of the presentdisclosure may be practiced without these specific details. In someinstances, well-known structures and components are summarily describedand/or shown in block diagram form in order to avoid obscuring theconcepts of the present disclosure.

With reference to FIGS. 1A and 1B, masonry fireplace 100 according to anexemplary embodiment is illustrated therein, in this configuration, thepanels 40 b, 50 b, and 60 b are factory built, and the whole structurecan be assembled on site using the factory built panels. The fireplace100 generally comprises a firebox 10 having a front end 12 and a rearend 14. The firebox 10 defines a cavity 30 and panels 40 b, 50 b, 60 bare preferably disposed in the cavity 30. In the illustrated embodiment,the fireplace 100 has a chimney outlet 20. However, the fireplace 100can be vent free, thus not requiring a chimney outlet. The fireplace 100can be adapted to burn various types of materials. For example, thefireplace 100 can be a wood and/or gas burning fireplace.

FIG. 2 illustrates the fireplace 100 of FIG. 1 with the panels 40 b, 50b, 60 b removed. The cavity 30 has a frame with a rear area 40 a, sideareas 50 a and a base area 60 a. The frame can comprise of at least onerail that defines the periphery of the cavity 30. The frame canoptionally comprise a plurality of panels, such as a rear wall 40 a,sidewalls 50 a and a base 60 a. Optionally, the panels 40 b, 50 b, 60 bcan comprise the frame areas 40 a, 50 a, 60 a.

The panels 40 b, 50 b, 60 b are preferably removably attached to therear area 40 a, side areas 50 a, and base area 60 a, respectively. Forexample, the panels 40 b, 50 b, 60 b can be riveted, bolted, screwed,welded, or connected with other connectors or fasteners to the cavityframe areas 40 a, 50 a, 60 a. In the illustrated embodiment, the panels40 b, 50 b, 60 b are in the form of masonry panels configured to receivebricks.

The panels 40 b, 50 b, 60 b are preferably made of metal. For example,the panels 40 b, 50 b, 60 b can be made of steel. Optionally, the panels40 b, 50 b, 60 b can be made of a sheet metal commonly used in thefireplace industry. However, the panels 40 b, 50 b, 60 b can optionallybe made of any material providing the necessary structural, thermal, andother characteristics required in fireplace construction.

The panels 40 b, 50 b, 60 b are preferably sized to substantially coverthe entire frame areas 40 a, 50 a, 60 a, respectively. Additionally, thepanels 40 b, 50 b, 60 b are preferably configured to provide adequatestructural support to masonry material disposed thereon. For example,the panels 40 b, 50 b, 60 b can have a thickness capable of providingsaid structural support.

According to the illustrated embodiment, the panels 40 b, 50 b, 60 bcomprise a running bond pattern. However, the panels 40 b, 50 b, 60 bcan comprise other patterns, such as a herringbone pattern, asillustrated in FIG. 3.

FIG. 4 illustrates a secure placement of bricks 95 a on a panel 90. Thepanel 90 provides a means for holding the bricks 92. The panel may bemade of metal, similar to the panels 40 b, 50 b, and 60 b described inFIG. 2. The panel 90 comprises a number of holes 91. The bricks 95 a areattached to the panel 92 by rivets 96. At least one rivet 96 getsinserted into each brick 95 a. At least one blind hole 93 in each brick95 a is aligned with one hole 91 in the panel 90. Through each alignedpair of holes 91 and 93, a rivet 96 is passed to fasten one brick 95 ato the panel 90. The rivets provide means for fastening the bricks tothe panel.

FIG. 5 and FIG. 6 show the rivet 96 as inserted into a brick 95 a of thepanel 90, through the hole of the brick 93 and the hole of the panel 91.Each rivet 96 has a shaft 97 and a mandrel 98. The rivet 96 has a head80, and may be made of aluminum. The dimension of the hole of the brick93, in an area adjacent to the hole of the panel 91, is wider than thedimension of the hole of panel 91. The hole of the panel 91 extends fromone side 102 to another side 103. For example, the hole of the brick 93may be approximately ¼″ wide and the diameter of the hole in the panelmay be approximately 3/16″. The diameters of the holes 91 and 93 withrespect to one another would have to be selected carefully to assurethat adequate support is obtained, especially in view of the size of therivet 96 and the size of brick 95 a being used The brick 95 a has anupper gap 200 which its diameter extends from one side 104 to anotherside 105 surrounding the tail 70 of the rivet 96. As shown in FIG. 6,once the top 75 of the mandrel 98, gets fully inserted into the shaft97, it 98 causes the tail 70 of the rivet 96 to expand. The expandedtail 70 portion of the rivet 96, forms a lock 99 inside each brick 95 a,and thereby further secures the brick 95 a to the panel 90. The brick 95a is locked into place when the tail 70 expands because it wedgesagainst the side of the hole 93 in the brick 95 a and the tail 70expands to a diameter larger than the diameter of the hole in the panel91.

FIG. 7 shows the rear view of the panel 90 of FIG. 4. The panel 90 maybe reinforced with a number of stiffeners 85. The stiffeners 85 providemeans for stiffening the panel so that the panel can securely andwithout bending, hold the bricks 95 a attached to it on the other side.An exemplary structure of a stiffener 85 is shown in FIG. 8. Thestiffener 85 may be formed as a channel and may be made of metal oranother substitute material. The stiffeners 85 runs along the groutingon the opposite side of the bricks.

FIG. 9 illustrates a method of fastening bricks 95 a onto the panel 90of FIG. 4. The method illustrated in FIG. 11 entails placing a number ofbricks 95 a on the panel 90 in the following way. For each brick 95 a,the side with at least one blind hole 93, must face the panel 90. Nextthe holes of the bricks 93 need to be aligned with the holes of thepanel 91. To help the alignment process, a frame 95 may be used. First,the frame 95 is placed on the panel and then the bricks 95 a are placedin each of the holders 95 b of the frame 95. At this point, the holes ofthe panel 91 are aligned with the holes of the bricks 93, and the rivets96 are passed through the holes of the panel 91 and then through theholes of the bricks 93. Once the bricks 95 a are fastened, then theframe 95 is removed. Next, the area in between the bricks 86, may begrouted by a grouting material such as cement.

FIG. 10 illustrates one method of cutting of the panel 90 once thebricks 95 a are installed. As shown, a cut is made to form an edge 88which is at an angle. This is done to fit the cut panel 90 in an areawhich has an edge with a similar angle. For example, each side of thelower panel 60 b in FIG. 2 is cut at an angle to fit the lower base part60 a of the fireplace 100. FIG. 11 illustrates another method of cuttingthe panel 90 with installed bricks 95 a. Here the cut is made along anedge 77 that is tapered. This for placing two panels 90 side to side atan angle with respect to one another. For example, in FIG. 2, the backpanel 40 b and one of the side panels 50 b may be cut along an edge 77to stand next to one another.

In general, some of the configurations described above are forfactory-built secured masonry surface coverings, so that they could beinstalled in a time and cost efficient manner, for various applications.The configurations are specially suited for fireplaces wherein theon-site building of such structures are difficult and/or prohibited bylocal safety regulations.

While the configurations described above are directed towardsfireplaces, it should be construed that the configurations are in no waylimited to fireplace implementation. The various configuration disclosedherein can be used to form fire pits, brick walls, brick counters, andother structures that can be made of bricks. For example, disclosedembodiments can form at least a portion of a countertop of an outdoorbarbecue.

The previous description is provided to enable any person skilled in theart to practice the various aspects described herein. Variousmodifications to these aspects will be readily apparent to those skilledin the art, and the generic principles defined herein may be applied toother aspects. Thus, the claims are not intended to be limited to theaspects shown herein, but are to be accorded the full scope consistentwith the language of the claims, wherein reference to an element in thesingular is not intended to mean “one and only one” unless specificallyso stated, but rather “one or more.” Unless specifically statedotherwise, the term “some” refers to one or more. All structural andfunctional equivalents to the elements of the various aspects describedthough out this disclosure that are known or later come to be known tothose of ordinary skill in the art are expressly incorporated herein byreference and are intended to be encompassed by the claims. Moreover,nothing disclosed herein is intended to be dedicated to the publicregardless of whether such disclosure is explicitly recited in theclaims. No claim element is to be construed under the provisions of 35U.S.C. 112, sixth paragraph, unless the element is expressly recitedusing the phrase “means for” or, in the case of a method claim, theelement is recited using the phrase “step for.”

1. An apparatus, comprising: a panel; a plurality of fasteners; and aplurality of bricks secured to the panel by the fasteners.
 2. Theapparatus of claim 1 further comprising a grouting material between thebricks.
 3. The apparatus of claim 1 wherein each of the fastenerscomprises a rivet.
 4. The apparatus of claim 3 wherein each of therivets comprises aluminum.
 5. The apparatus of claim 3 wherein each ofthe bricks comprises a surface in contact with the panel and at leastone blind hole in the surface, wherein each of said at least one blindhole surrounds a tail portion of one of the rivets.
 6. The apparatus ofclaim 5 wherein the panel comprises a plurality of holes, and whereineach of said at least one blind hole in each of the bricks is alignedwith one of the holes in the panel.
 7. The apparatus of claim 6 whereineach of said at least one blind hole in each of the bricks comprises adiameter greater than a diameter of the said one of the holes in thepanel aligned therewith.
 8. The apparatus of claim 7 wherein thediameter for each of said at least one blind hole in each of the bricksis approximately ¼″ and the diameter for each of the holes in the panelis approximately 3/16″.
 9. The apparatus of claim 1 wherein the panelcomprises a first surface in contact with the bricks and a secondsurface opposite the first surface, the second surface comprising one ormore stiffeners.
 10. The apparatus of claim 1 wherein the panel with thebricks secured thereon is cut along one edge at an angle with respect toan adjoining edge.
 11. The apparatus of claim 1 wherein each of thebricks along one edge of the panel comprises a tapered side.
 12. Amethod of assembling a masonry structure, comprising: arranging aplurality of bricks with a panel; and securing the bricks to the panelwith a plurality of fasteners.
 13. The method of claim 12 furthercomprising providing a grouting material between the bricks.
 14. Themethod of claim 12 wherein each of the fasteners comprises a rivet. 15.The method of claim 14 wherein each of the rivets comprises aluminum.16. The method of claim 14 wherein the bricks are arranged with thepanel by aligning at least one blind hole in each of the bricks with ahole in the panel, and wherein the bricks are secured to the panel bypassing one of the rivets through one of the holes in the panel intosaid at least one blind hole aligned therewith.
 17. The method of claim16 wherein the bricks are arranged with the panel using a frame.
 18. Themethod of claim 16 further comprising forming each of the holes in thepanel with a diameter and forming each of said at least one blind holein each of the bricks with a diameter greater than the diameter of saidone of the holes in the panel aligned therewith.
 19. The method of claim16 further comprising forming each of said at least one blind hole ineach of the bricks with an approximately ¼″ diameter and forming each ofthe holes in the panel with an approximately 3/16″ diameter.
 20. Themethod of claim 12 wherein the bricks are arranged with a first surfaceof the panel, the method further comprising attaching one or morestiffeners to a second surface of the panel opposite the first surface.21. The method of claim 12 further comprising cutting the panel with thebricks secured thereon at an angle with respect to an adjoining edge.22. The method of claim 12 further comprising cutting each of the bricksalong one edge of the panel to form a tapered side.
 23. An apparatus,comprising: a panel; a plurality of bricks; and means for fastening thebricks to the panel.
 24. A fireplace, comprising: a firebox having aplurality of walls defining an area for a fire, each of the walls havinga panel, a plurality of fasteners, and a plurality of bricks secured tothe panel by the fasteners.